Miller Electric Big 40 WG manual Standard Auxiliary Power, Optional Auxiliary Power Plant, Engine

Page 49

C.

Standard Auxiliary Power

 

 

 

 

 

Trouble

Remedy

 

 

No auxiliary power output; weld output

Reset receptacle circuit breakers.

okay.

 

 

 

No auxiliary power or weld output.

Disconnect equipment from auxiliary power receptacles during start-up.

 

 

 

 

 

Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent

 

 

check integrated rectifier SR1, capacitor C9, and the rotor.

 

 

 

 

 

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field

 

 

current regulator board PC1 (CC/CV models) (see Section 8-9).

 

 

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

High output at auxiliary power

Check engine speed, and adjust if necessary.

receptacles.

 

 

 

 

 

 

Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3.

 

 

Low output at auxiliary power

Check engine speed, and adjust if necessary.

receptacles.

 

 

 

 

 

 

Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check inte-

 

 

grated rectifier SR1, resistor R3, and capacitor C9.

 

 

D. Optional Auxiliary Power Plant

 

 

 

 

Trouble

Remedy

 

 

No or low output at optional auxiliary

Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).

power plant/receptacle RC5

 

(CC/CV models only).

 

 

 

 

 

 

Reset circuit breaker CB7 (see Section 7-2).

 

 

 

 

 

Reset circuit breaker CB5 (see Section 8-9).

 

 

 

 

 

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

 

 

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

 

 

PC1.

 

 

High output at optional auxiliary power

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

plant/receptacle RC5 (CC/CV models

 

only).

 

 

 

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC1.

 

 

Erratic output at optional auxiliary power

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

plant/receptacle RC5 (CC/CV models

PC1.

only).

 

 

 

 

E.

Engine

 

 

 

 

 

Trouble

Remedy

 

 

Engine will not crank.

Check battery, and replace if necessary.

 

 

 

 

 

Check battery connections and tighten if necessary.

 

 

 

 

 

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-9).

 

 

Have Factory Authorized Service Agent check engine wiring harness and components.

 

 

 

 

 

Check engine wiring harness plug connections.

 

 

 

 

 

Have Factory Authorized Service Agent check Engine Control switch S1.

 

 

 

OM-4405 Page 45

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Contents Processes OM-4405Description From Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interferenceConsignes DE SÉ Curité Lire Avant Utilisation Signification des symbolesUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs é lectromagné tiques Principales normes de sé curitéLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions SpecificationsWeld, Power, And Engine Specifications DefinitionsVolt-Ampere Curves For CC Models Dimensions, Weights, And Operating AnglesMIG Mode Stick ModeTIG Mode Volt-Ampere Curves for CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional AC Power Plant Curves AC Auxiliary Power Curve12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load 15 kVA/kW Three-Phase Auxiliary Power Plant No Weld LoadInstalling Welding Generator See Sections 4-2 InstallationUsing Lifting Eye Mounting Welding Generator Installing Exhaust PipeWelding Unit In Place Bolting Unit In Place To Bolt Unit In PlaceDo not overfill battery cells Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerConnect Negative Cable Last Connecting The BatteryEngine Prestart Checks Coolant Recovery TankFuel OilSelecting Weld Cable Sizes Connecting To Weld Output TerminalsRef 862-A / 048 720-K / 802 Socket Information Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section Operating Welding Generator CC ModelsDo not switch under load Engine Indicator LightsEngine Starting Controls To StartRemote Amperage Control On CC Models Optional OM-4405 Front Panel Controls For CC/CV Models See Section Operating Welding Generator CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch RunningSet Remote Set Range Remote Voltage/Amperage Control On CC/CV Models OptionalProcess Set RemoteVolt And 240 Volt Receptacles Operating Auxiliary EquipmentThree-Phase Power Connection Single-Phase Power Connection Single-Phase Auxiliary PowerRear Of Panel 240 V 15 a AC South African Receptacle RC1 Optional Auxiliary Power ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 Maintenance Label Maintenance & Troubleshooting50 h Routine Maintenance100 h 250 h500 h Inspecting And Cleaning Optional Spark Arrestor Muffler1000 h Stop engine and let coolServicing Air Cleaner Maximum Adjusting Engine Weld/Power SpeedEngine Speed Adjusting Engine Idle SpeedNo Load Tools Needed 1/2 Adjusting Governor SensitivityServicing Fuel And Lubrication Systems Overload Protection Press button to reset breakerDiagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsFault Condition 20s Start Engine With No Load AppliedWelding CC Models TroubleshootingWelding CC/CV Models Repair or replace wire feederTacle see Section Optional Auxiliary Power Plant Standard Auxiliary PowerEngine Shutdown switch is released Out Wiring harness and componentsAnt temperature is too high see Sections 4-7 Or coolant temperature is too high see Sections 4-7OM-4405 Circuit Diagram For CC Welding Generator Electrical Diagrams201 991-A Circuit Diagram For CC/CV Welding Generator 201 992-A Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-4405 107 106 101 105 103 Parts ListCC only 104 -4 or See FIG 108Dia Part Description Dia Part Description Mkgs Quantity Control Box Assembly CC Models Control Box Assembly CC Models -1 Item Control Box Assembly CC/CV Models 177 CONN, body 5 terminal to engine control switch S1 193 Panel, Front w/Components CC Models MS1 Panel, Front w/Components CC/CV Models -1 Item Panel, Front w/Components CC/CV ModelsPC6 192 Generator Generator -1 Item Main Rectifier Assembly Your distributor also gives ServiceSupport Miller Electric Mfg. Co Owner’s Record

Big 40 WG specifications

The Miller Electric Big 40 WG is a versatile and powerful welding generator designed to meet the demands of professionals in the field. Known for its reliability and robust performance, the Big 40 WG is the ideal choice for those who require both welding capabilities and a portable power source.

One of the standout features of the Big 40 WG is its ability to produce a substantial output of up to 10,000 watts of continuous power. This ensures that users have enough capacity to run various tools and equipment, making it perfect for job sites where electricity may not readily be available. The generator is powered by a Kohler Command PRO engine, renowned for its durability and efficiency, ensuring that users can depend on its performance even in the toughest conditions.

The machine offers a dual capability for electric welding and stick welding, which enables users to tackle a variety of applications, from light maintenance tasks to heavy-duty industrial jobs. The Big 40 WG features an easy-to-use control panel, equipped with clear indicators and outputs that simplify operation. Whether you need to switch between welding modes or adjust settings, the intuitive design allows for quick responses and seamless operation.

In terms of technology and innovation, the Big 40 WG includes advanced features such as an automatic idle speed adjustment, which increases fuel efficiency and reduces wear on the engine. This technology not only helps save on fuel costs but also minimizes noise levels, providing a more pleasant working environment.

Another key characteristic of the Big 40 WG is its portability. Engineered with a lightweight frame and built-in lifting hooks, it is easy to transport and maneuver, making it an excellent choice for on-site work. The rugged construction ensures that the generator can withstand the rigors of outdoor use, enhancing its lifespan and reliability.

For those in search of a welding generator that delivers on performance, functionality, and portability, the Miller Electric Big 40 WG stands out as a preferred option. Its combination of powerful output, advanced technologies, and user-friendly features makes it a valuable tool for professionals across various industries, ensuring they can complete their jobs effectively and efficiently, no matter where they are.
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